Blister package

ABSTRACT

A child-resistant package for a product is provided. The package comprises a double cover comprised of separate outer and inner layers, wherein the outer layer is disposed adjacent the inner layer, and a barrier disposed adjacent the inner layer of the double cover, wherein the inner layer and the barrier together define at least one compartment into which a product can be positioned. Also included are embodiments where the cover is a single layer and the bottom barrier is a double layer, and where both the cover and barrier are multiple layers. Included in the invention is a method of making a child-resistant package consistent with the package of the invention.

FIELD OF THE INVENTION

[0001] The present invention relates to packaging, and more specificallyto child-resistant packaging for dosed products.

BACKGROUND OF THE INVENTION

[0002] It is known to use blister packages to contain small articlessuch as pharmaceutical or dose form products. These packages allow theuser to access the product by applying pressure to the blister to forcethe product from an individual blister or capsule through a rupturablelayer.

[0003] Known blister packages comprise a first sheet of transparent ortranslucent thermoformable material such as polyvinyl chloride orpolystyrene having a plurality of flexible bubbles or blisters preformedtherein and projecting outwardly from one surface to define separatecompartments for individual doses of a product,typically a single pillor capsule, and a second sheet to cover the product. The second layer isoften made from a rupturable foil so that the user can push the productfrom the bubble side out through the foil. This construction did notoffer much in the way of child resistance, and presented a potentialhazard to children.

[0004] In order to render blister packages resistant to access bychildren, improved child-resistant blister packages have been developed.Exemplary structures of such child-resistant blister packages, as wellas exemplary methods of forming such packages, are disclosed in U.S.Pat. No. 6,161,699 to Gartland, which is hereby incorporated byreference herein.

[0005] Despite the fact that such child-resistant packages have improvedsafety characteristics, there is room for further improvements. Many ofthe known package-forming methods and package constructions, althoughoffering varying degrees of child resistance, sometimes compromisedaccessibility. Specifically, in some cases, known methods andconstructions made the product so inaccessible that even adults hadtrouble accessing the product. This later case is especially problematicwhere older adults or others who have lost some degree of manualdexterity are the users of the products.

[0006] Thus, there remains a need for an improved packaging method andconstruction that provide the desired level of resistance to a childwhile maintaining acceptable levels of accessibility for adults.

SUMMARY OF THE INVENTION

[0007] The present invention includes a child-resistant package for adose form product and a method of forming a child-resistant package forsuch a dose form product. According to one exemplary embodiment, theinvention provides a child-resistant package for a product comprising adouble cover comprised of separate outer and inner layers, wherein theouter layer is disposed adjacent the inner layer, and a barrier isdisposed adjacent the inner layer of the double cover. The inner layerand the barrier together define at least one compartment into which aproduct can be positioned.

[0008] In another exemplary embodiment of the invention, achild-resistant package for a product is provided which comprises acover and a double barrier disposed adjacent the cover, where the doublebarrier comprises separate outer and inner layers. In this embodiment,the outer layer is disposed adjacent the inner layer and the inner layerof the double barrier and the cover together define at least onecompartment into which a product can be positioned.

[0009] The invention also provides a method of forming a child-resistantpackage for a product. According to one exemplary embodiment, the methodincludes the steps of forming a double cover by disposing an outer layeradjacent an inner layer, the double cover defining at least one cavity.The method also includes the steps of placing a product in the cavity ofthe double cover and disposing a barrier adjacent the inner layer of thedouble cover, thereby defining at least one compartment between theinner layer of the double cover and the barrier in which the product iscontained.

[0010] Yet another embodiment of the method according to the presentinvention includes a method of forming a child-resistant package for aproduct including the steps of forming a double barrier by disposing anouter layer adjacent an inner layer, placing a product in a cavity of acover, and disposing the cover adjacent the inner layer of the doublebarrier. In this way, at least one compartment is formed between theinner layer of the double barrier and the cover in which the product iscontained.

[0011] The present invention also includes embodiments where both thecover and barrier are multi-layered. In such embodiments, the cover ismulti-layered and the product is disposed between the multi-layeredcover and a multi-layered barrier.

BRIEF DESCRIPTION OF THE FIGURES

[0012] The features of the invention believed to be novel and theelements characteristic of the invention are set forth withparticularity in the appended claims. The figures are for illustrationpurposes only and are not drawn to scale. The invention itself, however,both as to organization and method of operation, may best be understoodby reference to the detailed description that follows taken inconjunction with the accompanying drawings in which:

[0013]FIG. 1 is a cross-sectional side view of a portion of oneembodiment of the present invention in which a double cover is disposedatop a barrier;

[0014]FIG. 2 is an illustration of the embodiment of FIG. 1 but with anexaggerated view of bonding adhesives for illustration purposes;

[0015]FIG. 3 is a cross-sectional side view of a portion of anotherembodiment of the present invention in which a cover is disposed atop adouble barrier;

[0016]FIG. 4 is a cross-sectional side view of a portion of yet anotherexemplary embodiment in which both the cover is double layered and thebarrier is double layered;

[0017]FIG. 5 is a cross-sectional side view of yet another embodiment inwhich each of the layers of a double barrier is multi-layered;

[0018]FIG. 6 shows an exemplary embodiment of a ten-product packageconsistent with aspects of the present invention;

[0019]FIG. 7 shows the embodiment of FIG. 5 but with a card disposedatop the cover of the package; and

[0020]FIG. 8 shows the compilation of each layer in accordance with anexemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0021] This invention will now be described with reference to specificembodiments selected for illustration in the figures. It will beappreciated that the spirit and scope of this invention is not limitedto the embodiments selected for illustration. Instead, the scope of thisinvention is defined separately in the appended claims. Also, it will beappreciated that the drawings are not rendered to any particularproportion or scale.

[0022] The present invention includes child-resistant packages andmethods for packaging dose form products. Generally, the packagesaccording to the present invention are optionally formed with three ormore layers, with the packaged product disposed within a bubble or othercompartment formed between an inner layer and an outer layer. Theproducts which can be packaged in accordance with the present inventioninclude many varieties, most notably dose form products such aspharmaceuticals in pill or capsule form. Other products to which thepresent invention can be applied include, without limitation,medicaments (in pill, tablet, capsule, or lozenge form), drugs,vitamins, cosmetics, foods, pharmaceutical products; pharmaceuticalproducts, devices, and any other product for which dose-formconsumption, or use, is desired.

[0023] One embodiment of the present invention includes achild-resistant package for a dose form product comprising a doublecover and a single barrier. This embodiment is comprised of separateouter and inner layers, wherein the outer layer is disposed adjacent theinner layer, and a barrier is disposed adjacent the inner layer of thedouble cover. The inner layer and the barrier together define at leastone compartment into which a product can be positioned.

[0024]FIG. 1 shows such a package embodiment of the present invention,generally designated by the numeral “10,” where the cover is formed fromtwo layers and the barrier layer is formed from one layer. The package10 has a cover including an outer cover layer 100 and an inner coverlayer 110. More specifically, outer cover layer 100 of package 10 isdisposed atop, but adjacent to, inner cover layer 110. Together outercover layer 100 and inner cover layer 110 therefore form adouble-layered cover that, in the illustrated embodiment, includes abubble 120. Disposed below the two layered-cover is a barrier such as abacking layer 130. Barrier 130 is disposed adjacent inner cover layer110 of the double cover to enclose a product 140 within the compartmentformed by the bubble 120 and barrier 130.

[0025] Generally, each layer can be comprised of either foil, film,plastic or paper, or combinations thereof. Each respective layer isoptionally bonded, using an appropriate adhesive or other attachmentmaterial or method, to its adjacent layers, where contact is madebetween them. In other words, with the exception of the bubble area,inner cover layer 110 can be bonded to barrier 130, and with theexception of the air space 150 defined between the inner cover layer 110and the outer cover layer 100 (discussed below), outer cover layer 100can be bonded to inner cover layer 110.

[0026] In an exemplary embodiment, outer cover layer 100 is comprised ofa transparent film, such as a polyethylene or polyvinyl chloride orother polymeric film, and inner cover layer 110 is comprised of either asimilar transparent polymeric film, plastic, paper, or opaque foilmaterial. In the former embodiment, the user is allowed to see product140, but where light could be damaging to the product, such as reducingits shelf life, opaque foil or some other light-blocking orlight-reducing material would be preferred. In this embodiment, theouter cover layer can be comprised if a tough, penetration resistantpolymeric film such that access to the product can only be made throughthe barrier.

[0027] It is also optional that a space, either air, vacuum or inertgas, is provided between inner cover layer 110 and outer cover layer100. This, interstitial space 150 allows penetration through outer coverlayer 100 (when penetration occurs, although outer cover layer 110 isdesigned, as noted above, to be penetration-resistant) withoutpenetration of inner cover layer 110.

[0028] Barrier 130 is optionally comprised of paper, plastic, film, orfoil, or other suitable materially, and is optionally bonded to, in thecase of the embodiment illustrated in FIG. 1, inner cover layer 110 overat least a portion of inner cover layer 110 that is not raised to form acompartment such as bubble 120 for product 140.

[0029] In an exemplary embodiment, generally designated by the numeral“20” in FIG. 2, there is a region of contact between inner cover layer110 and barrier 130 immediately adjacent bubble 120 where no bondingexists. No-bond region 200 is shown in FIG. 2 and allows for the peelingaway of barrier 130 in that no-bond region so that product 140 can beaccessed. FIG. 2 shows such an embodiment in detail, with featuresdeliberately exaggerated and shown out of scale for the purpose ofillustration. FIG. 2 shows adhesive 230 in exemplary locations as wellas no-bond region 200 set apart from bonded region 210 by a perforation220. The user can thus peel barrier 130 away from inner cover layer 110beginning at perforation 220, thereby providing access to the product140.

[0030] In another embodiment of the invention, a child-resistant packagefor a product is provided which comprises a cover and a double barrierdisposed adjacent the cover, where the double barrier comprises separateouter and inner layers. In this embodiment, the outer layer is disposedadjacent the inner layer and the inner layer of the double barrier andthe cover together define at least one compartment into which a productcan be positioned. This embodiment is similar to the first embodimentdescribed above but the bubble is comprised of only one layer and thebarrier is comprised of multiple layers.

[0031]FIG. 3 shows an embodiment, generally designated by the numeral“30,” with cover layer 300 disposed around product 140. Inner barrier,layer 310 and cover layer 300 together define a compartment optionallyconfigured in the form of a bubble 320. Outer barrier layer 330 isdisposed adjacent inner barrier layer 310. Materials and adhesives orother bonding methods are the same as those described above in regard toFIG. 1. In this embodiment, the main difference is that the user mustfirst peel away outer barrier layer 330 before being able to penetrateor otherwise remove inner barrier 310.

[0032]FIG. 4 shows yet another exemplary embodiment of the presentinvention, generally designated by the numeral “40,” which isessentially a combination of the embodiments shown in FIGS. 1 and 3.Specifically, FIG. 4 shows an embodiment that can be considered adouble-double containment embodiment. Product 140 is disposed within acompartment such as a bubble 400, which is formed by inner cover layer410 and outer cover layer 420. An optional air space 430 is disposedbetween layers 410 and 420. A double barrier layer is disposed belowproduct 140 and is comprised of inner barrier layer 440 and outerbarrier layer 450.

[0033] In order to access product 140 from the blister package 40 shownin FIG. 4, the user can peel away outer barrier layer 450 and thenremove inner barrier layer 440. Removal of inner barrier layer 440 istypically accomplished by the user pulling on a tap or perforatedportion of inner barrier layer 440, and peeling or tearing it away.

[0034] Alternatively, the user can peel away outer barrier layer 450 andthen remove a product-containing blister (formed from a portion of theinner cover layer 410 and the inner barrier layer 440) from the spacebetween the outer barrier layer 450 and the outer cover layer 420. Theremoval of the blister can be facilitated by the absence of adhesionbetween (1) the inner cover layer 410 of the product-containing blisterand the outer cover layer 420 and (2) the inner barrier layer 440 ofthe, product-containing blister and the outer barrier layer 450. Onceremoved from the outer barrier layer 450 and the outer cover layer 420,the product-containing blister can be opened by the user either byremoving the inner barrier layer 440 to access the product 140 or bypushing the product 140 through the inner barrier layer 440 by pressingthe inner cover layer 410 against the product 140.

[0035]FIG. 5 shows yet a more specific embodiment, generally designatedby the numeral “50,” wherein each of inner barrier layer 440 and outerbarrier layer 450 are comprised of two or more layers. In thisembodiment, inner barrier layer 440 is a laminate of outer paper layer510 and inner foil layer 520. Outer barrier layer 450 is comprised ofperforated paper layer 530 and peel-away polymeric layer 540.

[0036] In order to access product 140 for the exemplary embodiment ofpackage 50, peel-away polymeric layer 540 is peeled-away, perforatedpaper layer 530 is torn away, and inner barrier 440 (comprised of acombination or lamination of the paper layer 510 and foil layer 520) ispeeled away or otherwise removed or pierced to access product 140.

[0037]FIG. 6 shows another version of the embodiment shown in FIG. 5,which is generally designated by the numeral “60.” Package 60 is adouble-double containment blistercard package for ten (10) dose-formproducts. FIG. 6 shows the outer cover layer 420 having recesses 611disposed therein to assist in a user's grabbing and peeling away ofportions of the inner barrier layer 440. In FIG. 6, inner cover layer410 is shown together with inner barrier layer 440, and the innerbarrier layer 440 is provided with lines of perforations so thatdistinct portions of the inner barrier layer 440 can be separated fromthe inner cover layer 410. The inner cover layer 410 and the innerbarrier layer 440 together define the bubbles or compartments in whichthe product is placed.

[0038] Outer barrier layer 450 is comprised of perforated paper layer530 and a pair of peel-away polymeric layers 540. This outer barrierlayer 450 is disposed on or adjacent inner barrier layer 440, which inturn is placed adjacent inner cover layer 410, which is in turn placedadjacent or into outer cover layer 420 as shown by the arrows in FIG. 6.In order to access product 140 in this embodiment 60, peel-awaypolymeric layer 540 is peeled-away, along with perforated paper layer530, and inner barrier layer 440 (comprised of the paper layer 510/foillayer 520 laminate) is peeled away or otherwise removed to accessproduct 140 disposed within inner cover layer 410.

[0039]FIG. 7 shows an additional embodiment, generally designated by thenumeral “70,” where outer card 700 is disposed on top of the blistercardpackages described above. Typically, outer card 700 is disposed atop thepackage for labeling or other packaging purposes. Outer card 700 simplyhas holes disposed therein to allow for the presence of each blister orbubble 120.

[0040]FIG. 8 shows an embodiment, generally designated by the numeral“80,” similar to that shown in FIG. 6 but with the addition of outercard 700 shown in FIG. 7. In this embodiment, and consistent with themethod described below, the product is put into inner cover layer 410,before inner barrier layer 440 is placed thereon. At this point, aproduct is disposed within and between inner cover layer 410 and innerbarrier layer 440. This combination is then inserted into outer coverlayer 420, which together are put into outer card 700 so that individualblisters extend through openings in the outer card 700. Outer card 700is attached to outer barrier 450, which is then folded along line 800 toenclose the product, inner barrier layer 440, inner cover layer 410, andouter cover layer 420. Bonding, using adhesives or other methods, iscontemplated between layers as appropriate and consistent with the abovedescription.

[0041] The invention also includes a method of forming a child-resistantpackage for a product. The method comprises the steps of forming adouble cover by disposing an outer layer adjacent an inner layer, thedouble cover defining at least one cavity. The double cover is asdefined above. The method also includes the steps of placing a productin the cavity of the double cover and disposing a barrier adjacent theinner layer of the double cover, thereby defining at least onecompartment between the inner layer of the double cover and the barrierin which the product is contained. The barrier is as defined above. Inthis embodiment, the cover or bubble formed is comprised of two layers.

[0042] Yet another embodiment of the method according to the presentinvention includes a method of forming a child-resistant package for aproduct comprising the steps of forming a double barrier by disposing anouter layer adjacent an inner layer, placing a product in a cavity of acover, and disposing the cover adjacent the inner layer of the doublebarrier. The cover and barrier are as defined above. In this way, atleast one compartment is formed between the inner layer of the doublebarrier and the cover in which the product is contained. This embodimentof the method is similar to the one described just above but the coveror bubble formed is comprised of only one layer.

[0043] Accordingly, while illustrated and described herein withreference to certain specific embodiments, the present invention is notintended to be limited to the embodiments and details shown. Rather, theappended claims are intended to include all embodiments andmodifications that may be made to these embodiments and details, whichare nevertheless within the true spirit and scope of the presentinvention.

What is claimed:
 1. A child-resistant package for a product comprising:a double cover comprised of separate outer and inner layers, wherein theouter layer is disposed adjacent the inner layer; and a barrier disposedadjacent the inner layer of the double cover; wherein the inner layerand the barrier together define at least one compartment into which aproduct can be positioned.
 2. The package of claim 1 wherein at leastone of the inner and outer layers of the double cover defines at leastone blister cavity.
 3. The package of claim 1 wherein at least one ofthe inner and outer layers of the double cover is formed from a film. 4.The package of claim 3 wherein the film is translucent.
 5. The packageof claim 1 wherein at least one of the inner and outer layers of thedouble cover is formed from a foil.
 6. The package of claim 1 whereinthe outer layer of the double cover is formed from a film and the innerlayer of the double cover is formed from a foil.
 7. The package of claim1 wherein each of the outer and inner layers defines at least oneblister cavity integrally formed therein and projecting from one sidethereof, together forming a double blister cover.
 8. The package ofclaim 7 wherein each of the outer and inner layers of the double coveris formed from a film.
 9. The package of claim 1 wherein the barrier iscomprised of at least two separate layers.
 10. The package of claim 9wherein the barrier is formed from any one or more of foil, film,plastic, or paper.
 11. The package of claim 10 wherein the barrier has afrangible section overlying each compartment, the frangible sectionbeing defined by a perforated or scored line in the barrier.
 12. Amethod for forming a child-resistant package for a product, said methodcomprising the steps of: (a) forming a double cover by disposing anouter layer adjacent an inner layer, the double cover defining at leastone cavity; (b) placing a product in the cavity of the double cover; and(c) disposing a barrier adjacent the inner layer of the double cover,thereby defining at least one compartment between the inner layer of thedouble cover and the barrier in which the product is contained.
 13. Themethod of claim 12 wherein the forming step comprises forming at leastone blister cavity in at least one of the inner and outer layers of thedouble cover.
 14. The method of claim 12 wherein the forming stepcomprises disposing a film adjacent a foil.
 15. The method of claim 12wherein the forming step comprises disposing a film adjacent a film. 16.The method of claim 12 wherein the disposing step comprises laminating afoil to the side of the inner layer opposite the outer layer.
 17. Themethod of claim 16 wherein the disposing step further comprisesdisposing a backing adjacent the foil opposite the inner layer of thedouble cover.
 18. The method of claim 7 wherein the backing is formedfrom any one or more of film, plastic, paper, or foil.
 19. The method ofclaim 17 further comprising defining a frangible section in the backingoverlying each cavity.
 20. A child-resistant package for a productcomprising: a cover; and a double barrier disposed adjacent the cover,said double barrier comprising separate outer and inner layers, whereinthe outer layer is disposed adjacent the inner layer; wherein the innerlayer of the double barrier and the cover together define at least onecompartment into which a product can be positioned.
 21. The package ofclaim 20 wherein the inner layer of the double barrier is formed fromany one or more of foil, film, plastic or paper.
 22. The package ofclaim 20 wherein the outer layer of the double barrier is formed fromany one or more of foil, film, plastic or paper, or combinationsthereof.
 23. The package of claim 20 wherein the inner layer of thedouble barrier is formed from any one or more of foil, film, plastic, orpaper, or combinations thereof.
 24. The package of claim 20 wherein theinner layer of the double barrier is a foil and paper laminate.
 25. Thepackage of claim 20 wherein the inner layer of the double barrier isaccessible only after at least partial removal of the outer layer of thedouble barrier.
 26. The package of claim 20 wherein the cover is adouble cover comprised of separate outer and inner layers, wherein theouter layer is disposed adjacent the inner layer.
 27. A method forforming a child-resistant package for a product, said method comprisingthe steps of: (a) forming a double barrier by disposing an outer layeradjacent an inner layer; (b) placing a product in a cavity of a cover;and (c) disposing the cover adjacent the inner layer of the doublebarrier, thereby defining at least one compartment between the innerlayer of the double barrier and the cover in which the product iscontained.